Electrode configurations for electrolytic cells and related methods

ABSTRACT

In one embodiment, an electrolytic cell for the production of aluminum from alumina includes: at least one anode module having a plurality of anodes; at least one cathode module, opposing the anode module, wherein the at least one cathode module comprises a plurality of cathodes, wherein the plurality of anodes are suspended above the cathode module and extending downwards towards the cathode module, wherein the plurality of cathodes are positioned extending upwards towards the anode module, wherein each of the plurality of anodes and each of the plurality of cathodes are alternatingly positioned, wherein the plurality of anodes is selectively positionable in a horizontal direction relative to adjacent cathodes, wherein the anode module is selectively positionable in a vertical direction relative to the cathode module, and wherein a portion of each of the anode electrodes overlap a portion of adjacent cathodes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a non-provisional patent application of and claimspriority to U.S. provisional patent application Ser. No. 62/313,266,filed Mar. 25, 2016, the entirety of which is hereby incorporated byreference.

FIELD

The present invention relates to apparatus and methods for producingaluminum metal and more particularly, to apparatus and methods forproducing aluminum metal by the electrolysis of alumina.

BACKGROUND

Hall-Héroult electrolytic cells are utilized to produce aluminum metalin commercial production of aluminum from alumina that is dissolved inmolten electrolyte (a cryolite “bath”) and reduced by a DC electriccurrent using a consumable carbon anode. Traditional methods andapparatus for smelting alumina utilize carbon anodes that are consumedslowly and generate CO2, a “greenhouse gas.” Traditional anode shapesand sizes also limit electrolysis of the reactant (dissolved alumina),which travels to the middle of the anode bottom for reaction. This leadsto a phenomenon called, “anode affect” that results in the generation ofCF₄, another regulated “greenhouse” gas. Besides the traditionalcommercial aluminum smelter, the prior art also includes aluminumsmelter designs where the anodes and cathodes have a verticalorientation, e.g., as described in U.S. Pat. No. 5,938,914 to Dawless,entitled, Molten Salt Bath Circulation Design For An Electrolytic Cell,which is incorporated by reference herein in its entirety.Notwithstanding, alternative electrode and aluminum smelter designsremain of interest in the field.

SUMMARY

Generally, the various embodiments of the present disclosure aredirected towards vertical electrode configurations for electrolyticallyproducing non-ferrous metal (e.g. aluminum) in an electrolysis cell. Asdescribed herein, anode modules (e.g. each module configured with aplurality of vertically oriented, inert anodes) is configured (e.g.attached) to a longitudinal beam, where the beam is configured to spanacross the open, upper end of the electrolysis cell. The longitudinalbeam is configured to be attached to or otherwise coupled tocomponents/lift mechanisms to adjust (e.g. raise or lower) the beam, andthus, raise or lower the corresponding anode modules that are coupled tothe beam. With the cathode modules positioned along (and attached to)the cell bottom, the vertical adjustment of the beams has acorresponding adjustment of the anode-cathode overlap (i.e. raised beamraises the anode modules and decreases the ACO, lowered beam lowers theanode modules and increases the ACO). Also, in some embodiments, theindividual anode modules are configured to be adjustable in theirgeneral horizontal position along the longitudinal beam spanning thecell. As such, the anode module is designed/configured to be loosened inits coupling attachment to the module and enabled to move the modulealong the beam. Thus, the anodes are shifted to modify the anode-cathodedistance between a group of anodes in the adjusted module and thecorresponding group of cathodes in the cathode module. In someembodiments, the anode to cathode distance is adjusted during preheatingor electrolytic production of metal (e.g. to promote a generally uniformanode-to-cathode distance). In some embodiments, the anode-cathodedistance (ACD) is adjusted during metal production. In some embodiment,the anode-cathode overlap (ACO) is adjusted during metal production. Insome embodiments, the anode-cathode distance (ACD) and ACO are adjustedduring metal production.

The disclosed subject matter relates to an electrolytic cell for theproduction of aluminum from alumina that has: at least one anode modulehaving a plurality of anodes, wherein each of the plurality of anodes isan oxygen-involving electrode; at least one cathode module, opposing theanode module, wherein the at least one cathode module comprises aplurality of cathodes, wherein the each of the plurality of anodes andeach of the plurality of cathodes have surfaces thereon that arevertically oriented and spaced one from another, wherein the cathodesare wettable, and wherein the at least one cathode module is coupled toa bottom of the electrolytic cell; a cell reservoir; an electrolytedisposed within the cell reservoir; and a metal pad disposed within thecell reservoir, wherein the plurality of anodes are at least partiallyimmersed in the electrolyte and suspended above the cathode module andextending downwards towards the cathode module, wherein the plurality ofcathodes are completely immersed in the electrolyte, wherein theplurality of cathodes are positioned in the cell reservoir extendingupwards towards the anode module, wherein each of the plurality ofanodes and each of the plurality of cathodes are alternatinglypositioned within the cell reservoir, wherein the plurality of anodes isselectively positionable in a horizontal direction relative to adjacentcathodes, wherein the anode module is selectively positionable in avertical direction relative to the cathode module, and wherein a portionof each of the anode electrodes overlap a portion of adjacent cathodes.

In another embodiment, the plurality of anodes form an least one row onthe anode module.

In another embodiment, the plurality of cathodes form an at least onerow on a cathode module.

In another embodiment, adjacent anodes in the at least one row of anodeshave a gap therebetween.

In another embodiment, adjacent cathodes in the at least one row ofcathodes have a gap therebetween.

In another embodiment, a horizontal distance between the anode and thecathode is in a range of ¼″ to 6″.

In another embodiment, a vertical overlap of the anode and the cathodeis in the range of 1″ to 100″.

In another embodiment, the anode is a plate with a rectangularcross-sectional shape that is 1″ to 75″ in width, 5″ to 100″ in heightand ¼″ to 10″ in thickness.

In another embodiment, the anode is a plate with a rectangularcross-sectional shape with radiused corners having a width in the rangeof 1″ to 75″ in width, 5″ to 100″ in height and ¼″ to 10″ in thicknessand a corner radius of ⅛″ to 1″.

In another embodiment, the anode is a plate with a rounded rectangularcross-sectional shape with radiused ends having a width in the range of1″ to 75″ in width, 5″ to 100″ in height and ¼″ to 10″ in thickness andan end radius of ⅛″ to 3″.

In another embodiment, the anode has an elliptical cross-sectional shapewith a major axis in the range of 1″ to 30″, a minor axis in the rangeof ¼″ to 5″ and a height in the range of 5″ to 50″.

In another embodiment, the anode has a circular cross-sectional shapewith a radius in the range of ¼″ to 6″ and a height in the range of 5″to 75″.

In another embodiment, the cathode is a plate with a rectangularcross-sectional shape having a width in the range of 1″ to 75″ in width,5″ to 100″ in height and ⅛″ to 5″ in thickness.

In another embodiment, the cathode module includes a plurality ofcathodes forming at least one row on the cathode module with adjacentcathodes in a row having a gap therebetween and wherein the plurality ofcathodes have a rectangular cross-sectional shape having a dimensions inthe range of 1″ to 40″ in width, 5″ to 75″ in height and ⅛″ to 5″ inthickness and a gap in the range of 1/16″ to 5″ therebetween.

In another embodiment, the cathode module includes a plurality ofcathodes forming at least one row on a cathode module with adjacentcathodes in a row having a gap therebetween and wherein the plurality ofcathodes have a circular cross-sectional shape having a radius in therange of ⅛″ to 3″, a height in the range of 5″ to 75″ and a gap in therange of 1/16″ to 2″ therebetween.

In another embodiment, the at least one cathode includes a plurality ofcathodes forming at least one row on a cathode module with adjacentcathodes in a row having a gap therebetween and wherein the plurality ofcathodes have a rounded rectangular cross-sectional shape havingdimensions in the range of ¼″ to 3″ in width, 5″ to 75″ in height and ⅛″to 3″ in thickness and a gap in the range of 1/16″ to 3″ therebetween.

In another embodiment, the cathode module includes a plurality ofcathodes forming at least one row on a cathode module with adjacentcathodes in a row having a gap therebetween and wherein the plurality ofcathodes have an elliptical cross-sectional shape having a minor axis inthe range of ¼″ to 3″ a major axis in the range of 1″ to 8″ and a heightin the range of 5″ to 75″ and a gap in the range of 1/16″ to 3″therebetween.

In another embodiment, the anode module includes a plurality of anodesdisposed on the anode module in an array forming a plurality of rows andthe cathode module includes a plurality of cathodes disposed on thecathode module in an array forming a plurality of rows, wherein theplurality of rows of anodes and the plurality of rows of cathodes areinterleaving, and wherein the plurality of anodes have a cross-sectionalshape of at least one of rectangular, rectangular with radiused edges,rounded rectangular, circular, or elliptical, and the plurality ofcathodes have a cross-sectional shape of at least one of rectangular,rectangular with radiused edges, rounded rectangular, circular, orelliptical.

In another embodiment, the anode module has a profile in a planeperpendicular to a direction of extension of the anodes with a firstdimension larger than a second dimension, the plurality of rows ofanodes are disposed either parallel or perpendicular to the firstdimension.

In another embodiment, a vertical distance between an upper surface ofthe electrolyte and an upper end of the cathode is in a range of ⅛″ to10″.

In another embodiment, a positioning apparatus is coupled to the atleast one anode module, wherein the positioning apparatus is configuredto selectively position the at least one anode module in a verticaldirection relative to the cathode module, and wherein the positioningapparatus is configured to selectively position the plurality of anodesin a horizontal direction relative to adjacent cathodes.

In another embodiment, a method for producing aluminum metal by theelectrochemical reduction of alumina, comprises: passing current betweenan anode and a cathode through an electrolytic bath of an electrolyticcell, the cell comprising: (a) passing current between an anode and acathode through an electrolytic bath of an electrolytic cell, the cellcomprising: (i) at least one anode module having a plurality of anodes,wherein each of the plurality of anodes is an oxygen-involvingelectrode, (ii) at least one cathode module, opposing the anode module,wherein the at least one cathode module comprises a plurality ofcathodes, wherein each of the plurality of anodes and each of theplurality of cathodes have surfaces thereon that are vertically orientedand spaced one from another, wherein the cathodes are wettable, andwherein the at least one cathode module is coupled to a bottom of theelectrolytic cell, (iii) a cell reservoir, (iv) an electrolyte disposedwithin the cell reservoir, and (v) a metal pad disposed within the cellreservoir, wherein the plurality of anodes are at least partiallyimmersed in the electrolyte and suspended above the cathode module andextending downwards towards the cathode module, wherein the plurality ofcathodes are completely immersed in the electrolyte, wherein theplurality of cathodes are positioned in the reservoir extending upwardstowards the anode module, wherein each of the plurality of anodes andeach of the plurality of cathodes are alternatingly positioned withinthe cell reservoir, wherein the plurality of anodes is selectivelypositionable in a horizontal direction relative to adjacent cathodes,wherein the anode module is selectively positionable in a verticaldirection relative to the cathode module, and wherein a portion of eachof the anode electrodes overlap a portion of adjacent cathodes; (b)feeding a feed material into the electrolytic cell; and (c) adjustingthe anode module in a vertical direction relative to the cathode module.

In another embodiment, the feed material is electrolytically reducedinto a metal product.

In another embodiment, the metal product is drained from the cathodes tothe cell bottom to form a metal pad.

In another embodiment, a metal product is produced having a purity ofP1020.

In another embodiment, adjusting the anode module comprises raising theat least one anode module to decrease an overlap of the portion of eachof the anode electrodes relative to the portion of adjacent cathodes.

In another embodiment, adjusting the anode module comprises lowering theat least one anode module to increase an overlap of the portion of eachof the anode electrodes relative to the portion of adjacent cathodes.

In another embodiment, a method for producing aluminum metal by theelectrochemical reduction of alumina, comprises: (a) passing currentbetween an anode and a cathode through an electrolytic bath of anelectrolytic cell, the cell comprising: (i) at least one anode modulehaving a plurality of anodes, wherein each of the plurality of anodes isan oxygen-involving anode, (ii) at least one cathode module, opposingthe anode module, wherein the at least one cathode module comprises aplurality of cathodes, wherein each of the plurality of anodes and eachof the plurality of cathodes have surfaces thereon that are verticallyoriented and spaced one from another, wherein the cathodes are wettable,and wherein the at least one cathode module is coupled to a bottom ofthe electrolytic cell, (iii) a cell reservoir, (iv) an electrolytedisposed within the cell reservoir, and (v) a metal pad disposed withinthe cell reservoir, wherein the plurality of anodes are at leastpartially immersed in the electrolyte and suspended above the cathodemodule and extending downwards towards the cathode module, wherein theplurality of cathodes are completely immersed in the electrolyte,wherein the plurality of cathodes are positioned in the cell reservoirextending upwards towards the anode module, wherein each of theplurality of anodes and each of the plurality of cathodes arealternatingly positioned within the cell reservoir, wherein theplurality of anodes is selectively positionable in a horizontaldirection relative to adjacent cathodes, wherein the anode module isselectively positionable in a vertical direction relative to the cathodemodule, and wherein a portion of each of the anode electrodes overlap aportion of adjacent cathodes; (b) feeding a feed material into theelectrolytic cell; and (c) adjusting the plurality of anodes in ahorizontal direction relative to adjacent cathodes.

In another embodiment, adjusting the plurality of anodes comprisesadjusting the plurality of anodes in a horizontal direction such that ahorizontal spacing is substantially similar on either side of the anodesin the anode module.

In another embodiment, the feed material is electrolytically reducedinto a metal product.

In another embodiment, the metal product is drained from the cathodes tothe cell bottom to form a metal pad.

In another embodiment, a metal product is produced having a purity ofP1020.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, referenceis made to the following detailed description of exemplary embodimentsconsidered in conjunction with the accompanying drawings.

FIG. 1 is a partially schematic cross-sectional view of an electrolyticcell in accordance with an embodiment of the present disclosure.

FIG. 2 is a perspective view of a pair of interleaved anode and cathodemodules in accordance with an embodiment of the present disclosure.

FIG. 3 is a side view of a portion of interleaved anode and cathodemodules in accordance with an embodiment of the present disclosure.

FIG. 4 is a partially cross-sectional, perspective view of anelectrolytic cell in accordance with an embodiment of the presentdisclosure like FIG. 1, but with a cross-section taken perpendicular tothat of FIG. 1.

FIG. 5 is a perspective view of an array of interleaved anode andcathode modules in accordance with another embodiment of the presentdisclosure.

FIG. 6 is a partially phantom plan view of an anode-cathode modulewithin an electrolytic cell in accordance with another embodiment of thepresent disclosure.

FIG. 7 is a series of diagrammatic cross-sectional views of a variety ofanodes in accordance with embodiments of the present disclosure.

FIG. 8 is a series of diagrammatic cross-sectional views of a variety ofcathodes in accordance with embodiments of the present disclosure.

FIGS. 9-13 are a series of diagrammatic plan views of a variety ofinterleaved anode and cathodes, in accordance with embodiments of thepresent disclosure.

FIG. 14 is a partially cross-sectional, perspective view of an exemplarypositioning apparatus coupled to an electrolytic cell for the productionof aluminum.

FIG. 15 is a partially cross-sectional, perspective view of an exemplarypositioning apparatus coupled to an electrolytic cell for the productionof aluminum.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

FIG. 1 shows a schematic cross-section of an electrolytic cell 10 forproducing aluminum metal by the electrochemical reduction of aluminausing an anode and a cathode. In some embodiments, the anode is an inertanode. Some non-limiting examples of inert anode compositions include:ceramic, metallic, cermet, and/or combinations thereof. Some non-limningexamples of inert anode compositions are provided in U.S. Pat. Nos.4,374,050, 4,374,761, 4,399,008, 4,455,211, 4,582,585, 4,584,172,4,620,905, 5,279,715, 5,794,112 and 5,865,980, assigned to the assigneeof the present application. In some embodiments, the anode is anoxygen-involving electrode. An oxygen-involving electrode is anelectrode that produces oxygen during electrolysis. In some embodiments,the cathode is a wettable cathode. In some embodiments, aluminumwettable materials are materials having a contact angle with moltenaluminum of not greater than 90 degrees in the molten electrolyte. Somenon-limiting examples of wettable materials may comprise one or more aTiB₂, ZrB₂, SrB₂, carbonaceous materials, and combinations thereof.

The cell 10 has at least one anode module 12. In some embodiments, theanode module 12 has at least one of anode 12E, or a plurality of anodes12E, suspended above at least one cathode module 14 having at least onecathode 14E, or a plurality of cathodes 14E. The plurality of cathodes14E is positioned in the cell reservoir 16. The plurality of cathodes14E extend upwards towards the anode module 12. While a plurality ofanodes 12E and cathodes 14E of a specific number are shown in thevarious embodiments of the present disclosure, any number of anodes 12Eand cathodes 14E greater than or equal to 1 may be used to define ananode module 12 or a cathode module 14, respectively. In someembodiments, the cathode module 14 is fixedly coupled to the bottom ofthe cell 10. In some embodiments, the cathodes 14E are supported in acathode support 14B, which rests in a cell reservoir 16 on cathodeblocks 18, e.g., made from carbonaceous material in electricalcontinuity with one or more cathode current collector bars 20. In someembodiments, the cathode blocks 18 are fixedly coupled to the bottom ofthe cell 10. The reservoir 16 typically has a steel shell 16S and islined with insulating material 16A, refractory material 16B and sidewallmaterial 16C. The reservoir 16 is capable of retaining a bath of moltenelectrolyte (shown diagrammatically by dashed line 22) and a moltenaluminum metal pad therein. Portions of an anode bus 24 that supplieselectrical current to the anode modules 12 are shown pressed intoelectrical contact with anode rods 12L of the anode modules 12. Theanode rods 12L are structurally and electrically connected to an anodedistribution plate 12S, to which a thermal insulation layer 12B isattached. The anodes 12E extend through the thermal insulation layer 12Band mechanically and electrically contact the anode distribution plate12S. The anode bus 24 would conduct direct electrical current from asuitable source 26 through the anode rods 12L, the anode distributionplate 12S, anode elements, electrolyte 22 to the cathodes 14E and fromthere through the cathode support 14B, cathode blocks 18 and cathodecurrent collector bars 20 to the other pole of the source of electricity26. The anodes 12E of each anode module 12 are in electrical continuity.Similarly, the cathodes 14E of each cathode module 14 are in electricalcontinuity. The anode modules 12 may be raised and lowered by apositioning apparatus to adjust their position relative to the cathodemodules 14 to adjust the anode-cathode overlap (ACO). An exemplarypositioning apparatus is depicted in FIG. 14 and FIG. 15.

FIG. 14 depicts a perspective view of an exemplary apparatus 100 for theproduction of aluminum. In some embodiments, the at least one anodemodule 12 having a plurality of anodes 12E is supported above thecorresponding at least one cathode module 14 having a plurality ofcathodes 14E. In some embodiments, the at least one anode module 12 issupported by a positioning apparatus as depicted in FIG. 14. In someembodiments, the positioning apparatus comprises at least one span beam102. While the exemplary apparatus 100 depicted in FIG. 14, uses fourspan beams 102, any number of span beams greater than or equal to 1 maybe used in accordance with the number of anode modules 12 and cathodemodules 12 in the electrolytic cell.

The span beam 102 has a first end 104 and an opposing second end 106. Insome embodiments, the span beam 102 is supported by a first supportingapparatus 108 at the first end 104 and by a second supporting apparatus110 at the second end 106. Each of the supporting apparatuses 108, 110are positioned on a deck 140 of the sidewall 142. The span beam 102 isoriented perpendicular to the sidewall 142. In some embodiments, thesupporting apparatuses 108, 110 are coupled to the deck 140. In someembodiments, the span beam 102 can be raised or lowered by lifts 130coupled to the supporting apparatuses 108, 110.

The anode module 12 is coupled to the span beam 102 via a connectorapparatus 116. The connector apparatus 116 comprises a first portion 118in contact with and connected to a surface 120 of the anode module 12.In some embodiments, the first portion 118 is connected to the surface120 at a plurality of connection points. The connector apparatus 116further comprises a second portion 124. The second portion 124 has afirst end and an opposing second end. The first end of the secondportion 124 is coupled to, or integrally formed with, the first portion118. The second portion 124 extends vertically from the first portion124 toward the span beam 102. The connector apparatus 116 furthercomprises a third portion 126. The third portion 126 is coupled to thesecond end of the second portion 124. In some embodiments, the thirdportion 126 is clamped to the span beam 102. In some embodiments, thethird portion can be unclamped and allowed to move freely along thelength of the span beam 102 (i.e. in the direction shown by arrow 128)to allow for selective positioning of the plurality of anodes in ahorizontal direction relative to adjacent cathodes.

FIG. 15 depicts a perspective view of another exemplary apparatus 200for the production of aluminum. In some embodiments, the at least oneanode module 12 having a plurality of anodes 12E is supported above thecorresponding at least one cathode module 14 having a plurality ofcathodes 14E. In some embodiments, the at least one anode module 12 issupported by a positioning apparatus as depicted in FIG. 15. In someembodiments, the positioning apparatus comprises at least one bridge202.

The bridge 202 has a first end 204 and an opposing second end 206. Insome embodiments, the bridge 202 is supported by a supporting apparatus210 at the first end 204 and at the second end 206. The supportingapparatus 210 comprises a plurality of vertical supports 240, positionedon opposing decks 242 of the endwall 216. The bridge 202 is orientedperpendicular to the endwall 216 and parallel to the sidewalls. In someembodiments, each vertical support 240 is coupled to each correspondingdeck 242. During operation of the exemplary apparatus 200 for theproduction of aluminum, the exemplary apparatus can be heated to atemperature sufficient to result in expansion of the apparatus. In someembodiments, the vertical supports at one deck 242 are unlocked (i.e.free floating), thereby allowing the deck 242 of the apparatus 200 toexpand without deforming any portion of the apparatus 200.

The anode module 12 is coupled to the bridge 202 via a connectorapparatus 244. The connector apparatus 244 comprises a first portion 246in contact with and connected to a surface 222 of the anode module 12.In some embodiments, the first portion 246 is connected to the surface222 at a plurality of connection points. The connector apparatus 244further comprises a second portion 224. The second portion 224 has afirst end and an opposing second end. The first end of the secondportion 224 is coupled to, or integrally formed with, the first portion246. The second portion 224 extends vertically from the first portion246 toward the bridge 202. The connector apparatus 244 further comprisesa third portion 226. The third portion 226 is coupled to the second endof the second portion 224. In some embodiments, the third portion 226can be raised or lowered to adjust the anode module in a verticaldirection relative to the cathode module.

In some embodiments, the connector apparatus 244 can be adjusted alongthe length of the bridge 202 (i.e. in the direction shown by arrow 228)to allow for selective positioning of the plurality of anodes in ahorizontal direction relative to adjacent cathodes.

FIGS. 1 and 2 show two anode modules 12 and two cathode modules 14 withrectangular, plate-shaped anodes 12E and rectangular, plate-shapedcathodes 14E positioned in an interleaved relationship. FIG. 2 showsthat the anode modules 12 have an array of anodes 12E with a width oftwo and a depth of five electrode elements 12E. Each cathode module 14has an array with a width of one cathode 14E and a depth of fourcathodes 14E. As shall be described below, this is one of manyconfigurations contemplated by the present disclosure. This arrangementcould also be described as an electrolytic cell having verticalelectrode assemblies in which the anode and cathode elements arejuxtaposed in alternating parallel configuration to define a pluralityof adjacent cells. When electrolyte 22 is added into the reservoir 16,submerging the spaced, interleaved anodes 12E and cathodes 14E, aplurality of electrolytic cells 10 are formed. When alumina ore (notshown) is disbursed in the electrolyte 22 and a direct current isapplied through the anode and cathode modules 12, 14 and the electrolyte22, the alumina may be reduced to aluminum metal by disassociation insolution, reduction at the cathode and oxidation at the anode:2Al₂O₃→4Al (at cathode)+3O₂ (at anode). As electric current flowsthrough the anode modules 12 and cathode modules 14 of the cell 10,oxygen bearing ions present in the electrolyte are discharged at thesurface of the anodes 12E as O₂ gas. A cover, ducts and scrubber (notshown) may be provided to capture off gases. Aluminium formed in thecell 10 accumulates on the bottom (i.e. on the metal pad 114F of FIG. 3within the cell) thereof from which it is periodically tapped.

FIG. 3 shows an anode module 112 and a cathode module 114 with theelectrodes 112E and 114E thereof in an interleaved relationship. Theheight of the bath 122 relative to the cathodes 114 may be called the“bath-to cathode distance” or BCD. In one embodiment, the BCD may be inthe range of ⅛″ to 10″ and in another embodiment, ½″ to 6″. The anodemodule 112 can be raised and lowered (i.e. selectively positionable) inheight relative to the position of the cathode module 114, as indicatedby double ended arrow V. In some embodiments, the anodes 112E are notcompletely submerged in the bath and extend across the bath-vaporinterface during metal production. This vertical adjustability allowsthe “overlap” Y of the anodes and the cathodes to be adjusted. The levelof the electrolytic bath 22 (FIG. 1), the height of the anodeselectrodes 112E and the cathode elements 114E may require the adjustmentof the anode module 112 position relative to the cathode module 114 inthe vertical direction, to achieve a selected anode-cathode overlap(ACO) Y, as well as depth of submersion in the electrolyte 22. In someembodiments, as shown in FIG. 3, the anode electrodes 112E are at leastpartially immersed in the electrolyte and the cathode electrodes 114Eare completely immersed in the electrolyte. Changing the ACO Y can beused to change the cell resistance and maintain stable cell temperature.

There is also a horizontal spacing, which can be called theanode-cathode distance or “ACD” between the anodes 112E and the cathodes114E, as indicated by X1, the spacing between a cathode 114 E and theanode element 112E to its immediate left and X2, the spacing between acathode 114E and the anode 112E to its immediate right. As shown in FIG.3, the spacing Z between the centerlines CL of the anodes 112E and thecenterlines (not shown) of the cathodes, may be equal, such that thehorizontal spacing, X1, X2 of each cathode 114E from the correspondinganodes 112E will be consistent. As shown in FIG. 3, the spacing X1 maybe different, e.g., less than the spacing X2, in which case there willbe a preferential flow of current associated with the lesser spacing X1or X2. The spacing X1, X2 may be adjustable or fixed, as controlled bythe mechanical support structure for the anode modules 112. The positionof the cathode modules 114 may also be fixed or adjustable. To provide adesired anode-cathode-distance (ACD), a spacer may be provided that isinterposed between at least one opposing anode 112E and cathode element114E.

The dimensional range of the spacing Z for the combination of anodes112E and cathodes 114E depends upon the thickness of the anodes 112E andcathodes 114E, as well as the anode-cathode distance (ACD). Thedimensional range of the spacing for X1 and X2 for the anodes 112E andcathodes 114E having the above described dimensional ranges will be ¼″to 6″, in some embodiments, ¼″ to 5″, in some embodiments ¼″ to 3″. Thedimensional range for the overlap Y, for the anodes 112E and cathodes114E will be 1″ to 100″, in some embodiments, 4″ to 75″, in someembodiments, 6″ to 35″ and in some embodiments 8″ to 25″.

The anodes 112E may be monolithic or composite, having an internalportion made from a metallic conductor and an outer portion that isformed from a material adapted to resist oxidation and corrosion due toexposure to the molten electrolyte 22 in a cell 10. The anodes 112E maybe ceramic-based, e.g., oxides of iron, titanium, zinc, cobalt, andcopper, ferrites (nickel ferrites, copper ferrites, zinc ferrites,multi-element ferrites) and mixtures thereof; metallic-based, e.g.,copper, nickel, iron, cobalt, titanium, aluminium, zinc, tin, and/oralloys of one of more of these metals; or cermet based (mixtures ofoxides and metals, i.e., a composite material comprising at least oneceramic phase and one metallic phase). The cathodes 14E may be made fromcorrosion resistant, molten aluminium-wettable materials, such astitanium diboride, zirconium diboride, hafnium diboride, strontiumdiboride, carbonaceous materials and combinations thereof.

The opposed, vertically oriented electrodes 112E, 114E permit thegaseous phases (O₂), generated proximal thereto to detach therefrom andphysically disassociate from the anode 112 due to the buoyancy of the O₂gas bubbles in the molten salt electrolyte 22. Since the bubbles arefree to escape from the surfaces of the anode 112 they do not build upon the anode surfaces to form an electrically insulative/resistive layerallowing the build-up of electrical potential, resulting in highresistance and, high energy consumption. The anodes 112E may be arrangedin rows or columns with or without a side-to side clearance or gapbetween them to create a channel that enhances molten electrolytemovement, thereby improving mass transport and allowing dissolvedalumina to reach the surfaces of the anode module 112. The number ofrows of anodes 112E can vary from 1 to any selected number and thenumber of anodes 112E in a row can vary from 1 to any number. Thecathodes 114E may be similarly arranged in rows with or withoutside-to-side clearance (gaps) between them and may similarly vary in thenumber of rows and the number of cathodes 114E in a row from 1 to anynumber.

FIG. 4 shows the cell 10 of FIG. 1 in an orientation allowing thevisualization of the ACD (X1, X2) and overlap Y.

FIG. 5 shows two rows of an anode array of anode modules 212 and cathodemodules 214 like those shown in FIGS. 1 and 2. For anode modules 212 andcathode modules 214 having the range of dimensions described above inreference to FIGS. 1 and 2, the number of anode modules 212 and cathodemodules 214 in the array may be in the range of 1 to 64, in someembodiments 2 to 48 and in some embodiments 8 to 48 that would beaccommodated in a reservoir 16 (FIG. 1).

FIG. 6 shows an anode-cathode module 412 positioned within a cell 410 inaccordance with another embodiment of the present disclosure. The anodemodule 412 has five rows of anodes 412E that are closely spaced ortouching side-to-side on the longer dimension of the anode module 412.Three center rows of anodes have nine anodes 412E and two exterior rowshave eight anodes 412E to accommodate chamfered edges 412C. Thechamfered edges 412C may be used to allow adding alumina or aluminummetal tapping. Four rows of cathodes 414E, each four in number, areinterleaved with the rows of anodes 412E.

The anode cathode distance (ACD) is both consistent and the same oneither side of the anodes 412E and cathodes 414E, i.e., X1 and X2 areapproximately equal and may range in size, as described above inreference to FIG. 3. As noted above, the present disclosure contemplatesthat the ACD may be adjustable, such that X1 and X2 are not equal. Asnoted above, the anode module 412 may be adjustable in height relativeto the cathode module 414. The resultant overlap Y (See FIG. 3) mayrange from in size, as described above in reference to FIG. 3.

FIG. 7 shows a series of diagrammatic cross-sectional views of a varietyof anodes 512E, 612E, 712E, 812E and 912E in accordance with embodimentsof the present disclosure. Anode 512E has a rectangular cross-sectionalshape and may have dimensions in the range of 1″ to 75″ in width (W), 5″to 100″ in height (into and out of the plane of the drawing) and ¼″ to10″ in thickness (T). In some embodiments, the rectangularcross-sectional shape may have a width of 20″ to 75″, 40″ to 75″, 60″ to75″, 1″ to 55″, 1″ to 35″, or 1″ to 15″. In some embodiments, therectangular cross-sectional shape may have a height of 5″ to 80″, 5″ to60″, 5″ to 40″, 5″ to 20″, 20″ to 100″, 40″ to 100″, 60″ to 100″, or 80″to 100″. In some embodiments, the rectangular cross-sectional shape mayhave a thickness of 1″ to 10″, 2″ to 10″, 4″ to 10″, 6″ to 10″, 8″ to10″, 1″ to 8″, 1″ to 6″, 1″ to 4″, 1″ to 2″.

Anode 612E has a rectangular cross-sectional shape with radiused cornersand may have dimensions in the range of 1″ to 75″ in width, 5″ to 100″in height (into and out of the plane of the drawing), ¼″ to 10″ inthickness and radius of curvature R1 of ⅛″ to 1″. In some embodiments,the rectangular cross-sectional shape with radiused corners may have awidth of 20″ to 75″, 40″ to 75″, 60″ to 75″, 1″ to 55″, 1″ to 35″, or 1″to 15″. In some embodiments, the rectangular cross-sectional shape withradiused corners may have a height of 5″ to 80″, 5″ to 60″, 5″ to 40″,5″ to 20″, 20″ to 100″, 40″ to 100″, 60″ to 100″, or 80″ to 100″. Insome embodiments, the rectangular cross-sectional shape with radiusedcorners may have a thickness of 1″ to 10″, 2″ to 10″, 4″ to 10″, 6″ to10″, 8″ to 10″, 1″ to 8″, 1″ to 6″, 1″ to 4″, 1″ to 2″. In someembodiments, the rectangular cross-sectional shape with radiused cornersmay have a radius of curvature R1 of ¼″ to 1″, ½″ to 1″, ⅛″ to ½″, or ⅛″to ¼″.

Anode 712E has a rounded, rectangular cross-sectional shape withradiused ends and may have dimensions in the range of 1″ to 50″ inwidth, 5″ to 75″ in height (into and out of the plane of the drawing),¼″ to 6″ in thickness and radius of curvature R2 of ⅛″ to 3″. In someembodiments, the rounded, rectangular cross-sectional shape withradiused ends may have a width of 10″ to 50″, 20″ to 50″, 30″ to 50″,40″ to 50″, 1″ to 40″, 1″ to 30″, or 1″ to 20″, 1″ to 10″. In someembodiments, the rounded, rectangular cross-sectional shape withradiused ends may have a height of 5″ to 60″, 5″ to 40″, 5″ to 20″, 5″to 10″, 20″ to 75″, 40″ to 75″, or 60″ to 75″. In some embodiments, therounded, rectangular cross-sectional shape may have a thickness of 1″ to6″, 2″ to 6″, 4″ to 6″, ¼″ to 4″, ¼″ to 2″, or ¼″ to 1″. In someembodiments, the rounded, rectangular cross-sectional shape withradiused ends may have a radius of curvature R2 of ⅛″ to 3″, ⅛″ to 2″,⅛″ to 1″, 1″ to 3″, or 2″ to 3″.

Anode 812E has an elliptical cross-sectional shape with a major axis A1in the range of 1″ to 30″, a minor axis A2 in the range of ¼″ to 5″ anda height in the range of 5″ to 50″. In some embodiments, the ellipticalcross-sectional shape has a major axis A1 in the range of 1″ to 20″, 1″to 10″, 1″ to 5″, 5″ to 30″, 10″ to 30″, or 20″ to 30″. In someembodiments, the elliptical cross-sectional shape has a minor axis A2 inthe range of ¼″ to 3″, ¼″ to 1″, 1″ to 5″, or 3″ to 5″. In someembodiments, the elliptical cross-sectional shape has a height in therange of 5″ to 40″, 5″ to 30″, 5″ to 20″, 5″ to 10″, 10″ to 40″, 20″ to40″, or 30″ to 40″.

Anode 912E has a circular cross-sectional shape with a radius R3 in therange of ¼″ to 6″ and a height in the range of 5″ to 75″. In someembodiments, the circular cross-sectional shape has a radius R3 in therange of 1″ to 6″, 3″ to 6″, 5″ to 6″, ¼″ to 4″, ¼″ to 2″, or ¼″ to 1″.

While each of the anode 512E-912E cross-sections shown in FIG. 11 may beconsistent along the length of the respective anode 512E-912E, thecross-section may also vary along the length (height) of the anode,e.g., the anode may taper in any given direction, execute a periodicvariance, or otherwise vary in thickness and/or width cross-sectionalong the length (height) thereof.

FIG. 8 shows a series of diagrammatic cross-sectional views of a varietyof cathodes 1014E, 1114E, 1214E, 1314E, and 1414E in accordance withembodiments of the present disclosure. Cathode 1014E has a rectangularcross-sectional shape and may have dimensions in the range of 1″ to 75″in width (W), 5″ to 100″ in height (into and out of the plane of thedrawing) and ⅛″ to 5″ in thickness (T). In some embodiments, therectangular cross-sectional shape may have a width of 20″ to 75″, 40″ to75″, 60″ to 75″, 1″ to 55″, 1″ to 35″, or 1″ to 15″. In someembodiments, the rectangular cross-sectional shape may have a height of5″ to 80″, 5″ to 60″, 5″ to 40″, 5″ to 20″, 20″ to 100″, 40″ to 100″,60″ to 100″, or 80″ to 100″. In some embodiments, the rectangularcross-sectional shape may have a thickness of 1″ to 10″, 2″ to 10″, 4″to 10″, 6″ to 10″, 8″ to 10″, 1″ to 8″, 1″ to 6″, 1″ to 4″, 1″ to 2″.

Cathodes 1114E have a rectangular cross-sectional shape and may havedimensions in the range of 1″ to 40″ in width (W), 5″ to 75″ in height(into and out of the plane of the drawing) and ⅛″ to 5″ in thickness.They are spaced side-to-side by a gap G1 having dimensions in a range of1/16″ to 5″. In some embodiments, the rectangular cross-sectional shapemay have a width of 1″ to 30″, 1″ to 20″, 1″ to 10″, 10″ to 40″, 20″ to40″, or 30″ to 40″. In some embodiments, the rectangular cross-sectionalshape may have a height of 5″ to 60″, 5″ to 40″, 5″ to 20″, 20″ to 75″,40″ to 75″, or 60″ to 75″. In some embodiments, the rectangularcross-sectional shape may have a thickness of 1″ to 5″, 3″ to 5″, ⅛″ to3″, or ⅛″ to 1″. In some embodiments, the rectangular cross-sectionalshape may have a gap G1 having dimensions in a range of 1″ to 5″, 3″ to5, 1/16″ to 3″, or 1/16″ to 1″.

Cathodes 1214E have a circular cross-sectional shape and may havedimensions in the range of ⅛″ to 3″ in radius and 5″ to 75″ in height(into and out of the plane of the drawing). They are spaced one fromanother by a gap G2 having dimensions in a range of 1/16″ to 2″. In someembodiments, the circular cross-sectional shape may have a radius of ⅛″to 2″, ⅛″ to 1″, 1″ to 3″, or 2″ to 3″. In some embodiments, thecircular cross-sectional shape may have a height of 20″ to 75″, 40″ to75″, 60″ to 75″, 5″ to 55″, 5″ to 35″, or 5″ to 15″. In someembodiments, the circular cross-sectional shape may have a gap G2 havingdimensions in a range of ⅛″ to 2″, ¼″ to 2″, 1″ to 2″, 1/16″ to 1″,1/16″ to ¼″, or 1/16″ to ⅛″.

Cathodes 1314E have a rounded rectangular cross-sectional shape and mayhave dimensions in the range of ¼″ to 3″ in width (W), 5″ to 75″ inheight (into and out of the plane of the drawing) and ⅛″ to 3″ inthickness. They are spaced one from another by a gap G3 havingdimensions in a range of 1/16″ to 3″. In some embodiments, the roundedrectangular cross-sectional shape may have a width of ¼″ to 2″, ¼″ to1″, ¼″ to ½″, ½″ to 3″, 1″ to 3″, or 2″ to 3″. In some embodiments, therounded rectangular cross-sectional shape may have a height of 5″ to60″, 5″ to 40″, 5″ to 20″, 20″ to 75″, 40″ to 75″, or 60″ to 75″. Insome embodiments, the rounded rectangular cross-sectional shape may havea thickness of ⅛″ to 3″, ¼″ to 3″, 1″ to 3″, ⅛″ to 2″, ⅛″ to 1″, ⅛″ to½″, or ⅛″ to ¼″. In some embodiments, the rounded rectangularcross-sectional shape may have a gap G3 having dimensions in a range of1/16″ to 2″, 1/16″ to 1″, 1/16″ to ½″, ⅛″ to 3″, ¼″ to 3″, or 1″ to 3″

Cathodes 1414E have an elliptical cross-sectional shape and may havedimensions with a major axis in the range of 1″ to 8″, a minor axis inthe range of ¼″ to 3″ and a height in the range of 5″ to 75″. In someembodiments, the elliptical cross-sectional shape has a major axis inthe range of 1″ to 6″, 1″ to 4″, 1″ to 2″, 2″ to 8″, 4″ to 8″, or 6″ to8″. In some embodiments, the elliptical cross-sectional shape has aminor axis in the range of ¼″ to 2″, ¼″ to 1″, ½″ to 3″, or 1″ to 3″. Insome embodiments, the elliptical cross-sectional shape has a height inthe range of 5″ to 60″, 5″ to 40″, 5″ to 20″, 5″ to 10″, 20″ to 75″, 40″to 75″, or 60″ to 75″.

FIGS. 9-13 show diagrammatic views of a variety of interleaved anode andcathodes, in accordance with embodiments of the present disclosure.FIGS. 9-13 show that the rows of anodes 1512E . . . 2412 E and the rowsof cathodes 1514E . . . 2414E (and the channels there between that aredefined thereby) may be arranged in rows that may have a selectedorientation relative to a given cell 10. FIG. 9 shows two anode/cathodeconfigurations A and B, each featuring elongated rectangular thermalinsulation layers 1512B, 1612B. Anode module 1512 has five rows ofanodes 1512E, ten in number, that are closely spaced or touchingside-to-side along the longer dimension of the anode module 1512. Fourrows of cathodes 1514E, each four in number, are interleaved with therows of anodes 1512E. Anode module 1612 has eight rows of anodes 1612E,three in number per row, that are closely spaced or touchingside-to-side along the shorter dimension of the anode module 1612. Sevenrows of cathodes 1614E, each two in number, are interleaved with therows of anodes 1612E.

FIG. 10 shows two anode cathode configurations A and B, each featuringrectangular thermal insulation layers 1712B, 1812B with chamfers C.Anode module 1712 has six rows of anodes 1712E with circularcross-sectional shape. Each row, which extends across the smallerdimension of the anode module 1712, has eight anodes 1712E, except therow near the chamfers C, which has six. The anodes 1712E are spacedalong the shorter dimension of the anode module 1712. Five rows ofcathodes 1714E with a generally rectangular cross-sectional shape, eachrow having four cathodes 1714E, are interleaved with the rows of anodes1712E. Anode module 1812 has four rows of anodes 1812E having circularcross-sectional shape, each with either twelve (center rows) or elevenanodes (end rows near chamfer) per row, that are closely spaced alongthe longer dimension of the anode module 1812. Three rows of cathodes1814E, each with three cathodes 1814E in number, are interleaved withthe rows of anodes 1812E.

FIG. 11 shows two anode-cathode configurations A and B, each featuringrectangular thermal insulation layers 1912B, 2012B with chamfers C.Anode module 1912 has six rows of anodes 1912E with circularcross-sectional shape. Each row, which extends across the smallerdimension of the anode module 1912, has eight anodes 1912E, except therow near the chamfers C, which has six. The anodes 1912E are spacedalong the shorter dimension of the anode module 1912. Five rows ofcathodes 1914E with a generally rectangular cross-sectional shape, eachrow having six cathodes 1914E, are interleaved with the rows of anodes1912E. Anode module 2012 has four rows of anodes 2012E with a circularcross-sectional shape, each with either twelve (center rows) or elevenanodes (end rows near chamfer) per row, that are closely spaced alongthe longer dimension of the anode module 2012. Three rows of cathodes2014E, each with nine cathodes 2014E in number, are interleaved with therows of anodes 2012E.

FIG. 12 shows two anode-cathode configurations A and B, each featuringrectangular thermal insulation layers 2112B, 2212B with chamfers C.Anode module 2112 has six rows of anodes 2112E with circularcross-sectional shape. Each row, which extends across the smallerdimension of the anode module 2112, has eight anodes 2112E, except therow near the chamfers C, which has six. The anodes 2112E are spacedalong the shorter dimension of the anode module 2112. Five rows ofcathodes 2114E with a generally circular cross-sectional shape, each rowhaving fifteen cathodes 2114E, except for the row nearest the chamfers,which has thirteen, are interleaved with the rows of anodes 2112E. Anodemodule 2212 has four rows of anodes 2212E with a circularcross-sectional shape, each with either twelve (center rows) or elevenanodes (end rows near chamfer) per row, that are closely spaced alongthe longer dimension of the anode module 2212. Three rows of cathodes2214E having a circular cross-sectional shape, each with eithertwenty-three cathodes (center row) or twenty-two (end rows) in number,are interleaved with the rows of anodes 2212E.

FIG. 13 shows two anode-cathode configurations A and B, each featuringrectangular thermal insulation layers 2312B, 2412B with chamfers C.Anode module 2312 has six rows of anodes 2312E with circularcross-sectional shape. Each row, which extends across the smallerdimension of the anode module 2312, has eight anodes 2312E, except therow near the chamfers C, which has six. The anodes 2312E are spaced inrows along the shorter dimension of the anode module 2312. Five rows ofcathodes 2114E with a generally rectangular cross-sectional shape withradiused-ends, each row having eight cathodes 2314E are interleaved withthe rows of anodes 2312E. Anode module 2412 has four rows of anodes2412E with a circular cross-sectional shape, each with either twelve(center rows) or eleven anodes (end rows near chamfer) per row, that areclosely spaced along the longer dimension of the anode module 2412.Three rows of cathodes 2414E with a rectangular cross-sectional shapewith radiused ends, each with twelve cathodes, are interleaved with therows of anodes 2412E.

The above-described electrodes in the dimensional ranges disclosed maybe used to produce P1020 or better aluminum metal. The increased surfacearea of the electrodes per unit of cell volume may lead to higher ratesof production. The above described electrode structures may eliminationor reduction of CO₂ generation and reduce pollutants generated byHall-Héroult smelting, such as CF₄ and SO₂.

In some embodiments, a method for producing aluminum metal by theelectrochemical reduction of alumina, comprises: (a) passing currentbetween an anode and a cathode through an electrolytic bath of anelectrolytic cell, the cell comprising: (i) at least one anode modulehaving a plurality of anodes, wherein each of the plurality of anodes isan oxygen-involving anode, (ii) at least one cathode module, opposingthe anode module, wherein the at least one cathode module comprises aplurality of cathodes, wherein each of the plurality of anodes and eachof the plurality of cathodes have surfaces thereon that are verticallyoriented and spaced one from another, wherein the cathodes are wettable,and wherein the at least one cathode module is coupled to a bottom ofthe electrolytic cell, (iii) a cell reservoir, (iv) an electrolytedisposed within the cell reservoir, and (v) a metal pad disposed withinthe cell reservoir, wherein the plurality of anodes are at leastpartially immersed in the electrolyte and suspended above the cathodemodule and extending downwards towards the cathode module, wherein theplurality of cathodes are completely immersed in the electrolyte,wherein the plurality of cathodes are positioned in the cell reservoirextending upwards towards the anode module, wherein each of theplurality of anodes and each of the plurality of cathodes arealternatingly positioned within the cell reservoir, wherein theplurality of anodes is selectively positionable in a horizontaldirection relative to adjacent cathodes, wherein the anode module isselectively positionable in a vertical direction relative to the cathodemodule, and wherein a portion of each of the anode electrodes overlap aportion of adjacent cathodes; (b) feeding a feed material into theelectrolytic cell; and (c) adjusting the anode module in a verticaldirection relative to the cathode module.

In some embodiments of the above described method, the feed material iselectrolytically reduced into a metal product. In some embodiments ofthe above described method, the metal product is drained from thecathodes to the cell bottom to form a metal pad. In some embodiments ofthe above described method, a metal product is produced having a purityof P1020. In some embodiments of the above described method, adjustingthe anode module comprises raising the at least one anode module todecrease an overlap of the portion of each of the anode electrodesrelative to the portion of adjacent cathodes (e.g. decrease theanode-cathode overlap (ACO)). In some embodiments of the above describedmethod, adjusting the anode module comprises lowering the at least oneanode module to increase an overlap of the portion of each of the anodeelectrodes relative to the portion of adjacent cathodes. (e.g. increasethe anode-cathode overlap (ACO)).

In some embodiments, a method for producing aluminum metal by theelectrochemical reduction of alumina, comprises: (a) passing currentbetween an anode and a cathode through an electrolytic bath of anelectrolytic cell, the cell comprising: (i) at least one anode modulehaving a plurality of anodes, wherein each of the plurality of anodes isan oxygen-involving anode, (ii) at least one cathode module, opposingthe anode module, wherein the at least one cathode module comprises aplurality of cathodes, wherein each of the plurality of anodes and eachof the plurality of cathodes have surfaces thereon that are verticallyoriented and spaced one from another, wherein the cathodes are wettable,and wherein the at least one cathode module is coupled to a bottom ofthe electrolytic cell, (iii) a cell reservoir, (iv) an electrolytedisposed within the cell reservoir, and (v) a metal pad disposed withinthe cell reservoir, wherein the plurality of anodes are at leastpartially immersed in the electrolyte and suspended above the cathodemodule and extending downwards towards the cathode module, wherein theplurality of cathodes are completely immersed in the electrolyte,wherein the plurality of cathodes are positioned in the cell reservoirextending upwards towards the anode module, wherein each of theplurality of anodes and each of the plurality of cathodes arealternatingly positioned within the cell reservoir, wherein theplurality of anodes is selectively positionable in a horizontaldirection relative to adjacent cathodes, wherein the anode module isselectively positionable in a vertical direction relative to the cathodemodule, and wherein a portion of each of the anode electrodes overlap aportion of adjacent cathodes; (b) feeding a feed material into theelectrolytic cell; and (c) adjusting the plurality of anodes in ahorizontal direction relative to adjacent cathodes.

In some embodiments of the above described method, the plurality ofanodes is adjusted in a horizontal direction such that a horizontalspacing (e.g. the anode-cathode distance (ACD)) is the same, orsubstantially similar, on either side of the anodes in the anode module(i.e. when measuring the ACD on either side of an anode in the anodemodule to cathodes positioned on opposite sides of the anode). In someembodiments of the above described method, the feed material iselectrolytically reduced into a metal product.

In some embodiments of the above described method, the metal product isdrained from the cathodes to the cell bottom to form a metal pad. Insome embodiments of the above described method, a metal product isproduced having a purity of P1020.

The adjustment of the vertical or horizontal position of the anodemodule as described in embodiments above provides for increasedelectrical efficiency in electrolytic metal production. The adjustmentof the vertical or horizontal position of the anode module as describedin embodiments above also provides for reduced cell voltage drop (e.g.reduced electrical resistance). The adjustment of the vertical orhorizontal position of the anode module as described in embodimentsabove also provides for modified cell temperature; modified feed rate offeed material, and or optimized cell operating parameters.

It will be understood that the embodiments described herein are merelyexemplary and that a person skilled in the art may make many variationsand modifications without departing from the spirit and scope of thedisclosed subject matter. All such variations and modifications areintended to be included within the scope of the disclosure.

What is claimed is:
 1. An electrolytic cell, comprising: at least oneanode module having a plurality of anodes, wherein each of the pluralityof anodes is an oxygen-involving electrode; at least one cathode module;opposing the anode module, wherein the at least one cathode modulecomprises a plurality of cathodes, wherein each of the plurality ofanodes and each of the plurality of cathodes have surfaces thereon thatare vertically oriented and spaced one from another, wherein thecathodes are wettable, wherein the at least one cathode module iscoupled to a bottom of the electrolytic cell, and wherein a portion ofeach of the anodes overlaps a portion of adjacent cathodes; a cellreservoir configured to retain a bath of molten electrolyte and a moltenmetal pad disposed therewithin; and a positioning module coupled to theat least one anode module, configured to adjust a position of the atleast one anode module in a vertical direction relative to the cathodemodule; and to adjust a position of the plurality of anodes in ahorizontal direction relative to adjacent cathodes; wherein theplurality of anodes are configured to be at least partially immersed inthe bath of electrolyte when the plurality of anodes are suspended abovethe cathode module and extend downwards towards the cathode module;wherein the plurality of cathodes are configured to be completelyimmersed in the bath of electrolyte; wherein the plurality of cathodesare positioned in the cell reservoir extending upwards towards the anodemodule, and wherein each of the plurality of anodes and each of theplurality of cathodes are alternatingly positioned within the cellreservoir.
 2. The apparatus of claim 1, wherein the plurality of anodesform an at least one row on the anode module.
 3. The apparatus of claim2, wherein the plurality of cathodes form an at least one row on thecathode module.
 4. The apparatus of claim 3, wherein adjacent anodes inthe at least one row of anodes have a gap therebetween.
 5. The apparatusof claim 4, wherein adjacent cathodes in the at least one row ofcathodes have a gap therebetween.
 6. The apparatus of claim 5, wherein ahorizontal distance between two adjacent at least one row of anodes andthe at least one row of cathodes is in a range of ¼″ to 6″.
 7. Theapparatus of claim 1, wherein a vertical overlap of the anodes and thecathodes is in a range of 1″ to 100″.
 8. The apparatus of claim 1,wherein the anode is a plate with a rectangular cross-sectional shapethat is 1″ to 75″ in width, 5″ to 100″ in height and ¼″ to 10″ inthickness.
 9. The apparatus of claim 1, wherein the anode is a platewith a rectangular cross-sectional shape with radiused corners having awidth in the range of 1″ to 75″ in width, 5″ to 100″ in height and ¼″ to10″ in thickness and a corner radius of ⅛″ to 1″.
 10. The apparatus ofclaim 1, wherein the anode is a plate with a rounded rectangularcross-sectional shape with radiused ends having a width in the range of1″ to 75″ in width, 5″ to 100″ in height and ¼″ to 10″ in thickness andan end radius of ⅛″ to 3″.
 11. The apparatus of claim 1, wherein theanode has an elliptical cross-sectional shape with a major axis in therange of 1″ to 30″, a minor axis in the range of ¼″ to 5″ and a heightin the range of 5″ to 50″.
 12. The apparatus of claim 1, wherein theanode has a circular cross-sectional shape with a radius in the range of¼″ to 6″ and a height in the range of 5″ to 75″.
 13. The apparatus ofclaim 1, wherein the cathode is a plate with a rectangularcross-sectional shape having a width in the range of 1″ to 75″ in width,5″ to 100″ in height and ⅛″ to 5″ in thickness.
 14. The apparatus ofclaim 1, wherein the cathode module includes a plurality of cathodesforming at least one row on the cathode module with adjacent cathodes ina row having a gap therebetween and wherein the plurality of cathodeshave a rectangular cross-sectional shape having dimensions in the rangeof 1″ to 40″ in width, 5″ to 75″ in height and ⅛″ to 5″ in thickness anda gap in the range of 1/16″ to 5″ therebetween.
 15. The apparatus ofclaim 1, wherein the cathode module includes a plurality of cathodesforming at least one row on the cathode module with adjacent cathodes ina row having a gap therebetween and wherein the plurality of cathodeshave a circular cross-sectional shape having a radius in the range of ⅛″to 3″, a height in the range of 5″ to 75″ and a gap in the range of1/16″ to 2″ therebetween.
 16. The apparatus of claim 1, wherein thecathode module includes a plurality of cathodes forming at least one rowon the cathode module with adjacent cathodes in a row having a gaptherebetween and wherein the plurality of cathodes have a roundedrectangular cross-sectional shape having dimensions in the range of ¼″to 3″ in width, 5″ to 75″ in height and ⅛″ to 3″ in thickness and a gapin the range of 1/16″ to 3″ therebetween.
 17. The apparatus of claim 1,wherein the cathode module includes a plurality of cathodes forming atleast one row on the cathode module with adjacent cathodes in a rowhaving a gap therebetween and wherein the plurality of cathodes have anelliptical cross-sectional shape having a minor axis in the range of ¼″to 3″, a major axis in the range of 1″ to 8″, and a height in the rangeof 5″ to 75″, and a gap in the range of 1/16″ to 3″ therebetween. 18.The apparatus of claim 1, wherein the anode module includes a pluralityof anodes disposed on the anode module in an array forming a pluralityof rows and the cathode module includes a plurality of cathodes disposedon the cathode module in an array forming a plurality of rows, whereinthe plurality of rows of anodes and the plurality of rows of cathodesare interleaving, and wherein the plurality of anodes have across-sectional shape of at least one of rectangular, rectangular withradiused edges, rounded rectangular, circular, or elliptical, and theplurality of cathodes have a cross-sectional shape of at least one ofrectangular, rectangular with radiused edges, rounded rectangular,circular, or elliptical.
 19. The apparatus of claim 1, wherein the anodemodule has a profile in a plane perpendicular to a direction ofextension of the anodes with a first dimension larger than a seconddimension, and wherein a plurality of rows of anodes are disposed eitherparallel or perpendicular to the first dimension.
 20. The apparatus ofclaim 1, wherein a vertical distance between an upper surface of theelectrolyte and an upper end of the cathode is in a range of ⅛″ to 10″.21. The electrolytic cell of claim 1, wherein the positioning modulecomprises at least one span beam oriented perpendicularly to a sidewallof the electrolytic cell, each of the at least one anode modules beingconnected to one of the at least one span beam.
 22. The electrolyticcell of claim 21, wherein each of the at least one span beam issupported by supporting elements located at opposite ends of the atleast one span beam, the positioning module further comprising liftingsystems coupled to the supporting elements for raising or lowering theat least one span beam and the at least one anode modules connectedthereto.
 23. The electrolytic cell of claim 21, wherein each of the atleast one anode module is connected to the at least one span beam with aconnecting element having one end connected to the anode module and anopposite end equipped with a clamp configured to connect the connectingelement to the at least one span beam, the clamp being configured to beunclamped allowing as such the clamp and the connecting element to movealong a length of the at least one span beam to allow for positioningthe plurality of anodes in the horizontal direction relative to adjacentcathodes.
 24. The electrolytic cell of claim 1, wherein the positioningmodule comprises at least one bridge oriented perpendicularly to aendwall and parallel to a sidewall of the electrolytic cell, the atleast one anode modules being connected to one of the at least onebridge.
 25. The electrolytic cell of claim 24, wherein each of the atleast one bridge is supported by vertical supports positioned onopposing decks of the endwall, the at least one anode modules beingconnected to the at least one bridge via a connecting apparatuscomprising a first portion connected to a surface of the at least oneanode module.
 26. The electrolytic cell of claim 25, wherein the firstportion is connected to the surface of the at least one anode module ata plurality of connection points.
 27. The electrolytic cell of claim 25,wherein the connecting apparatus comprises a second portion having afirst end coupled to the first portion and an opposite second endextending vertically from the first portion toward the at least onebridge, the connecting apparatus further comprising a third portioncoupled to the second end of the second portion and configured for beingraised or lowered to adjust the at least one anode module in thevertical direction relative to the at least one cathode module.
 28. Theelectrolytic cell of claim 24, wherein the connecting apparatus isconfigured to be adjusted along a length of the at least one bridge toallow for positioning of the plurality of anodes in a horizontaldirection relative to adjacent cathodes.
 29. A method for producingaluminum metal by the electrochemical reduction of alumina, comprising:(a) passing current between an anode and a cathode through anelectrolytic bath of an electrolytic cell, the cell comprising: (i) atleast one anode module having a plurality of anodes, wherein each of theplurality of anodes is an oxygen-involving electrode, (ii) at least onecathode module, opposing the anode module, wherein the at least onecathode module comprises a plurality of cathodes, wherein each of theplurality of anodes and each of the plurality of cathodes have surfacesthereon that are vertically oriented and spaced one from another,wherein the cathodes are wettable, and wherein the at least one cathodemodule is coupled to a bottom of the electrolytic cell, (iii) a cellreservoir, (iv) an electrolyte disposed within the cell reservoir, and(v) a metal pad disposed within the cell reservoir, wherein theplurality of anodes are at least partially immersed in the electrolyteand suspended above the cathode module and extending downwards towardsthe cathode module, wherein the plurality of cathodes are completelyimmersed in the electrolyte, wherein the plurality of cathodes arepositioned in the cell reservoir extending upwards towards the anodemodule, wherein each of the plurality of anodes and each of theplurality of cathodes are alternatingly positioned within the cellreservoir, wherein the plurality of anodes is selectively positionablein a horizontal direction relative to adjacent cathodes, wherein theanode module is selectively positionable in a vertical directionrelative to the cathode module, and wherein a portion of each of theanode electrodes overlap a portion of adjacent cathodes; (b) feeding afeed material into the electrolytic cell; and (c) adjusting theplurality of anodes in a horizontal direction relative to adjacentcathodes.
 30. The method of claim 29, wherein adjusting the plurality ofanodes comprises adjusting the plurality of anodes in a horizontaldirection such that a horizontal spacing is substantially similar oneither side of the anodes in the anode module.
 31. The method of claim29, further comprising (d) electrolytically reducing the feed materialinto a metal product.
 32. The method of claim 31, further comprising:(e) draining the metal product from the cathodes to the cell bottom toform a metal pad.
 33. The method of claim 32, further comprisingproducing a metal product having a purity of P1020.